Twenty-four-cornered strengthening member for vehicles

ABSTRACT

A strengthening member for a motor vehicle and a vehicle including a strengthening member are provided. The strengthening member can have a cross-section that has twenty-four corners and includes sides and corners creating sixteen internal angles and eight external angles. The vehicle may include a strengthening member that has twenty-four corners and includes sides and corners creating sixteen internal angles and eight external angles.

TECHNICAL FIELD

The present disclosure relates generally to a strengthening member for a vehicle body or other structures. The present disclosure relates more specifically to a strengthening member having a twenty-four-cornered cross section and to motor vehicles including a strengthening member having a twenty-four-cornered cross section.

BACKGROUND

It is desirable, for vehicle strengthening members, to maximize impact energy absorption and bending resistance while minimizing mass per unit length of the strengthening member. Impact energy absorption may be maximized, for example, by assuring that the strengthening member compacts substantially along a longitudinal axis of the strengthening member upon experiencing an impact along this axis. Such longitudinal compaction may be referred to as a stable axial crush of the strengthening member.

When a compressive force is exerted on a strengthening member, for example, by a force due to a front impact load on a vehicle's front rail or other strengthening member in the engine compartment, the strengthening member can crush in a longitudinal direction to absorb the energy of the collision. In addition, when a bending force is exerted on a strengthening member, for example, by a force due to a side impact load on a vehicle's front side sill, B-pillar or other strengthening member, the strengthening member can bend to absorb the energy of the collision.

Conventional strengthening members rely on increasing the thickness and hardness of side and/or corner portions to improve crush strength. However, such increased thickness and hardness increases weight of the strengthening member and reduces manufacturing feasibility. It may be desirable to provide a strengthening assembly configured to achieve the same or similar strength increase as provided by the thickened sides and/or corners, while minimizing mass per unit length of the member, and maintaining a high manufacturing feasibility.

It may further be desirable to provide a strengthening member that can achieve increased energy absorption and a more stable axial collapse when forces such as front and side impact forces are exerted on the strengthening member, while also conserving mass to reduce vehicle weights and meet emission requirements. Also, it may be desirable to provide a strengthening member that can achieve improved energy absorption and bend when a bending force is exerted on the strengthening member. Additionally, it may be desirable to provide a strengthening member that possesses improved noise-vibration-harshness performance due to work hardening on its corners. In addition, it may be desirable, to provide a tunable strengthening member cross section configured to achieve strength increases (i.e., load carrying and energy absorption) over basic polygonal designs, while also allowing flexibility in design to meet a range of vehicle applications.

SUMMARY

In accordance with various exemplary embodiments of the present disclosure, a strengthening member for a motor vehicle is provided. The strengthening member has cross-section including twenty-four corners and including sides and corners creating sixteen internal angles and eight external angles.

In accordance with another aspect of the present disclosure, a strengthening member for a motor vehicle is provided. The strengthening member has a cross-section including twenty-four corners and including sides and corners creating internal angles and external angles that alternate between four consecutive internal angles and two consecutive external angles.

In accordance with a further aspect of the present disclosure, a vehicle that includes a strengthening member is provided. The strengthening member has a cross section including twenty-four corners and including sides and corners creating sixteen internal angle corners and eight external angle corners.

Additional objects and advantages will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the present teachings. The objects and advantages of the present disclosure will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the claimed subject matter. The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate exemplary embodiments of the present disclosure and together with the description, serve to explain principles of the present teachings.

BRIEF DESCRIPTION OF THE DRAWINGS

At least some features and advantages of the present teachings will be apparent from the following detailed description of exemplary embodiments consistent therewith, which description should be considered with reference to the accompanying drawings, wherein:

FIG. 1 illustrates cross section of a strengthening member having twenty-four corners cross section including sixteen internal angles and eight external angles in accordance with the present teachings;

FIGS. 2A-2B illustrate top and perspective views of a first exemplary embodiment of a strengthening member having a twenty-four-cornered cross section, with sixteen internal angles and eight external angles, as shown in FIG. 1;

FIGS. 3A-3B illustrate top and perspective views of a second exemplary embodiment of a strengthening member having twenty-four-cornered cross sections, with sixteen internal angles and eight external angles in accordance with the present teachings;

FIGS. 4A-4B illustrate top and perspective views of a third exemplary embodiment of a strengthening member having twenty-four-cornered cross sections, with sixteen internal angles and eight external angles in accordance with the present teachings;

FIGS. 5A-5B illustrate top and perspective views of a fourth exemplary embodiment of a strengthening member having twenty-four-cornered cross sections, with sixteen internal angles and eight external angles in accordance with the present teachings;

FIGS. 6A-6B illustrate top and perspective views of a fifth exemplary embodiment of a strengthening member having twenty-four-cornered cross sections, with sixteen internal angles and eight external angles in accordance with the present teachings;

FIGS. 7A-7B illustrate top and perspective views of a sixth exemplary embodiment of a strengthening member having twenty-four-cornered cross sections, with sixteen internal angles and eight external angles in accordance with the present teachings;

FIGS. 8A-8B illustrate top and perspective views of a seventh exemplary embodiment of a strengthening member having twenty-four-cornered cross sections, with sixteen internal angles and eight external angles in accordance with the present teachings;

FIG. 9 illustrates strengthening members of various cross sections having substantially the same thickness, substantially the longitudinal length, and cross-sectional dimensions along perpendicularly oriented transverse axes with substantially the same lengths;

FIG. 10 illustrates an exemplary quasi-static axial collapse of the strengthening members shown in FIG. 9;

FIG. 11 illustrates an exemplary dynamic crush of the strengthening members shown in FIG. 9;

FIG. 12 is a graph of the dynamic crush force and associated crush distance for the exemplary strengthening members shown in FIG. 9;

FIG. 13 is a graph of the dynamic axial crush energy and associated axial crush distance for the exemplary strengthening members shown in FIG. 9;

FIG. 14 illustrates an exemplary embodiment of a vehicle frame with several components for which a strengthening member having twenty-four-cornered cross sections, with sixteen internal angles and eight external angles can be used; and

FIG. 15 illustrates an exemplary embodiment of a vehicle upper body with several components for which a strengthening member having twenty-four-cornered cross sections, with sixteen internal angles and eight external angles can be used.

Although the following detailed description makes reference to exemplary illustrative embodiments, many alternatives, modifications, and variations thereof will be apparent to those skilled in the art. Accordingly, it is intended that the claimed subject matter be viewed broadly.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

Reference will now be made in detail to various exemplary embodiments, examples of which are illustrated in the accompanying drawings. The various exemplary embodiments are not intended to limit the disclosure. To the contrary, the disclosure is intended to cover alternatives, modifications, and equivalents of the exemplary embodiments. In the drawings and the description, similar elements are provided with similar reference numerals. It is to be noted that the features explained individually in the description can be mutually combined in any technically expedient manner and disclose additional embodiments of the present disclosure.

The present teachings contemplate strengthening members with twenty-four-cornered cross sections having substantially increased stiffness throughout the sides and corners without increasing thickness within the corners as done in conventional strengthening members. The strengthening members of the present disclosure are designed based in part on, for example, a variety of tunable parameters configured to achieve strength increases (i.e., load carrying and energy absorption) over basic polygonal designs (e.g., polygonal strengthening member cross sections having less or the same number of sides), while also allowing design flexibility to meet a range of vehicle applications.

In accordance with the present teachings, the shape of the strengthening members disclosed herein provides the strengthening member with stabilized folding, reduced crush distance, and increased energy absorption in response to an axially applied crash force. The shape also improves moisture shedding abilities of the strengthening member and permits a more customized fit with other vehicle components.

The strengthening members in accordance with the present teachings can achieve increased energy absorption and a more stable axial collapse when forces such as front and side impact forces are exerted on the strengthening member. Furthermore, the side lengths and configurations, and/or degrees of the internal and external angles, of the strengthening members in accordance with the present teachings can achieve a similar, if not greater, strength increase as thickened corners, while minimizing mass per unit length of the member and maintaining a high manufacturing feasibility because the member can be formed by stamping, bending, press forming, hydro-forming, molding, casting, extrusion, uniform or non-uniform roll forming, machining, forging, and/or other known manufacturing processes. Thus-formed sections can be joined via welding, brazing, soldering, adhesive bonding, fastening, press fitting or other known joining technologies.

Strengthening members in accordance with the present teachings can comprise, for example, steel alloys, titanium alloys, aluminum alloys, magnesium alloys, nylons, plastics, polymers, composites, fiber-reinforced composites, hybrid materials (i.e., multiple dissimilar materials), shape-memory materials, or any other suitable materials. Those of ordinary skill in the art would understand, for example, that the material used for a strengthening member may be chosen based at least in part on intended application, strength/weight considerations, cost, packaging space, and/or other design factors.

An exemplary embodiment of a cross section of a strengthening member 100 having twenty-four corners in accordance with the present teachings is illustrated in FIG. 1. The strengthening member 100 has twenty-four sides. The illustrated cross section of the strengthening member 100 comprises twenty-four sides having lengths S₁-S₂₄ and thicknesses T₁-T₂₄, sixteen internal corners with angles θ_(i1)-θ_(i16), and eight external corners with angles θ_(e1)-θ_(e8).

The perimeter of the twenty-four-sided cross section generally forms a polygon comprising a plurality of internal and external corners. As embodied herein and shown in FIG. 1, the polygon may be formed of alternating internal and external angles, and in particular, may be formed by alternating four consecutive internal corners/angles with two consecutive external corners/angles. This repeating pattern, which alternates between four consecutive internal corners/angles and two consecutive external corners/angles (i.e., an alternating four-in-two-out configuration), results in a cross section with up to four bisecting planes of symmetry. Under an axial and symmetric loading condition, strengthening members with symmetrical, polygonal cross sections, including the various embodiments of the present teachings, may have better load carrying capabilities and energy absorbing capabilities than those with asymmetrical, polygonal cross sections with an equivalent number of corners and sides. Furthermore, strengthening members with symmetrical, polygonal cross sections with more than two bisecting planes of symmetry (e.g., three bisecting planes of symmetry, or four-or-more bisecting planes of symmetry), including the various embodiments of the present teachings, may have better load carrying capabilities and energy absorbing capabilities than those with symmetrical, polygonal cross sections with two or fewer bisecting planes of symmetry and an equivalent number of corners and sides. However, as those of skill in the art will understand, use of asymmetrical cross-sections may offer other benefits that provide advantages that cannot be realized using a symmetrical cross-section. The present disclosure contemplates that a twenty-four-sided, twenty-four-cornered cross section, in accordance with the present teachings, may be either symmetrical or asymmetrical.

Depending upon the particular application and/or the desired features of the strengthening member, the lengths of the sides and the thicknesses of the sides of the twenty-four-sided, twenty-four-cornered strengthening member as well as the internal and external corner angles of the strengthening member can be varied (i.e., can be tuned) to achieve improved strength and other performance features (e.g., stability of folding pattern) compared to conventional strengthening member cross sections. Varying these features of the twenty-four-sided, twenty-four-cornered strengthening member may obviate the need for increased side and/or corner thickness. In accordance with various exemplary embodiments of the present teachings, the lengths of sides S₁-S₂₄, the thicknesses T₁-T₂₄ of the sides as well as the internal angles θ_(i1)-θ_(i16) and external angles θ_(e1)-θ_(e8) of the corner angles can be varied to a certain degree, as would be understood by one skilled in the art, for example in accordance with available packaging space within a vehicle.

In addition, in a strengthening member in accordance with the present teachings, each internal corner angle θ_(i1)-θ_(i16) of the strengthening member can range from about 30° to about 175°, and each external corner angle θ_(e1)-θ_(e8) of the strengthening member can range from about 45° to about 175°. In accordance with the present teachings, the internal angles θ_(i1)-θ_(i16) of the strengthening member may all be substantially the same, and similarly, the external angles θ_(e1)-θ_(e8) of the strengthening member may all be substantially the same. Additionally, the present teachings contemplate embodiments for which one or more of the internal angle(s) θ_(i1)-θ_(i16) are right angles as well as embodiments for which one, more than one, or all of the external angle(s) θ_(e1)-θ_(e16) are right angles. Additionally or alternatively, the present disclosure contemplates embodiments in which at least some of the internal angles θ_(i1)-θ_(i16) of the strengthening member differ from one another, and similarly, at least some of the external angles θ_(e1)-θ_(e8) of the strengthening member differ from one another. FIG. 1 illustrates an exemplary embodiment in which internal angles θ_(i1), θ_(i4), θ_(i5), θ_(i8), θ_(i9), θ_(i12), θ_(i13), and θ_(i16) are about 90°, internal angles θ_(i2), θ_(i3), θ_(i6), θ_(i7), θ_(i10), θ_(i11), θ_(i14), and θ_(i15) are about 135°, all of the external corner angles θ_(e1)-θ_(e8) are about 90°, and the aspect ratio is about 1:1.

In certain exemplary embodiments of the present disclosure, such as in an automotive application, for example, a length of each side S₁-S₂₄ of the strengthening member can range from about 10 mm to about 250 mm. In other exemplary embodiments, such as in an aircraft, spacecraft, watercraft, or building application, for example, a length of each side S₁-S₂₄ of the strengthening member may be larger.

In certain exemplary embodiments of the present disclosure, such as in an automotive application, for example, a thickness T₁-T₂₄ of the sides of the strengthening member can range from about 0.6 mm to about 6.0 mm. In other exemplary embodiments of the strengthening member, such as in an aircraft, spacecraft, watercraft, or building application, for example, a thickness T₁-T₂₄ of the sides of the strengthening member may be larger. In one exemplary embodiment, a thickness T₁-T₁₆ of each of the sides of the strengthening member may be about 3.3 mm. In another exemplary embodiment, a thickness T₁-T₁₆ of each of the sides may be about 2.3 mm. In another exemplary embodiment, a thickness T₁-T₁₆ of each of the sides may be about 2.2 mm. In some exemplary embodiments, the thickness T₁-T₁₆ of the sides is substantially the same as the thickness of the corners for each side. In some exemplary embodiments the thickness T₁-T₁₆ of each side wall, (e.g., side walls 202A-202X (see FIG. 2A)), can vary with respect to each other side wall. Alternatively or concurrently, the thickness T₁-T₂₄ can vary within each length of the sides S₁-S₂₄.

Top and perspective views of a first exemplary embodiment of a strengthening member 200 having a twenty-four-cornered cross section, with sixteen internal angles and eight external angles are illustrated in FIGS. 2A-2B, respectively. Strengthening member 200 has twenty-four corners 204A-P and 206A-H, and twenty-four side walls 202A-202X. Sixteen of the corners are internal angle corners 204A-204P and eight of the corners are external angle corners 206A-206H. Strengthening member 200 also has a first transverse axis 208, a second transverse axis 210, and a longitudinal axis 212. Although shown with its longitudinal axis 212 positioned substantially vertically, when strengthening member 200 (as well as all of the other various embodiments in accordance with the present teachings) is installed within a vehicle, the longitudinal axis 212 of the strengthening member may be oriented substantially horizontally.

The strengthening member 200 of FIGS. 2A-2B also has a uniform cross section along a length of the strengthening member 200, from a first end 218 to a second end 220 of the strengthening member 200. Additionally, the length of each side S₁-S₂₄ is approximately the same as illustrated in FIGS. 2A-2B. As also illustrated, each of eight of the internal angles are substantially the same, each of the other eight internal angles are substantially the same, and each of the external angles are substantially the same. In particular, each of eight of the internal angles are about 90°, each of the other eight internal angles are about 135°, and each external angle is about 90°. The thicknesses of each sidewall 202A-202X are also substantially the same.

Top and perspective views of an alternative exemplary embodiment of a strengthening member 300 having a twenty-four-cornered cross section, with sixteen internal angles and eight external angles, are illustrated in FIGS. 3A-3B, respectively. Strengthening member 300 differs from strengthening member 200 in several aspects. For example, as shown in FIGS. 3A and 3B, one or more of the side walls of the strengthening member may be angled with respect to the longitudinal axis 312 of the strengthening member to provide a taper to at least a portion of the shape of the strengthening member 300. As shown in FIGS. 3A-3B, strengthening member 300 is tapered along its length, from a first end 318 of the strengthening member 300 to a second end 320 of the strengthening member. The strengthening member 300 tapers along its length at an angle a, which can range from about 1° to about 65°. The degree of taper of each side wall may be substantially the same, or different side walls may exhibit differing degrees of taper. Tapering may be required due to component packaging constraints and/or to effectively couple, attach or otherwise bond other components to a strengthening member.

In the exemplary embodiment of FIGS. 3A-3B, internal angles θ_(i1), θ_(i4), θ_(i5), θ_(i8), θ_(i9), θ_(i12), θ_(i13), and θ_(i16) are about 90°; internal angles θ_(i2), θ_(i3), θ_(i6), θ_(i7), θ_(i10), θ_(i11), θ_(i14), and θ_(i15) are about 135°; and all of the external angles θ_(e) are about 90°. Also, as shown in FIGS. 3A-3B, strengthening member 300 includes recessed areas 314, 315, 316 and 317. Each recessed area 314, 315, 316 and 317 extends along the length of the strengthening member 300 from first end 318 to second end 320. In the disclosed exemplary embodiment of FIGS. 3A-3B, the lengths of each of the twenty-four sides are each approximately the same as the lengths of other sides when taken at any cross section along the longitudinal length of the strengthening member 300. However, the length of each side gradually/incrementally increases along the longitudinal axis 312 of the strengthening member 300 from first end 318 to second end 320 to provide the tapered shape. As noted above, the embodiment of FIGS. 3A-3B is exemplary, and therefore all of the contemplated embodiments with variations to the lengths and thicknesses of the sides and to the angles of the internal and external corner angles of the twenty-four-cornered cross sections, with sixteen internal angles and eight external angles, of the strengthening members in accordance with the present teachings are not shown in the figures, but based on the teachings herein, will be apparent to those of skill in the art.

Top and perspective views of an alternative exemplary embodiment of a strengthening member 400 having the twenty-four-cornered cross section, with sixteen internal angles and eight external angles, are illustrated in FIGS. 4A-4B, respectively. Similar to the strengthening member 200, strengthening member 400 has a uniform cross section along a length of the strengthening member 400, from a first end 418 to a second end 420 of the strengthening member 400. However, as shown in FIGS. 4A-4B, strengthening member 400 differs from strengthening members 200 and 300 in that the dimension-to-dimension ratio of the cross section of the strengthening member, taken along transverse axes 408, 410 is not 1:1; rather, the aspect ratio is about 6.5:10.0. FIGS. 4A-4B illustrate a strengthening member that has a first length 422 along a first (minor) transverse axis 408 and a second length 424 along a second (major) transverse axis 410, where the second transverse axis 410 is perpendicular to the first transverse axis 408. The aspect ratio of a strengthening member may be defined as [first length 422]:[second length 424]. In the exemplary embodiment of FIGS. 4A-4B, the internal corner angles θ_(i1), θ_(i4), θ_(i5), θ_(i8), θ_(i9), θ_(i12), θ_(i13), and θ_(i16) are not all same and internal corner angles θ_(i2), θ_(i3), θ_(i6), θ_(i7), θ_(i10), θ_(i11), θ_(i14), and θ_(i15) are not all the same. In particular, as shown in FIG. 4A, internal angles θ_(i1), θ_(i4), θ_(i9), and θ_(i12) have a first measurement, e.g., of about 70°; internal angles θ_(i5), θ_(i8), θ_(i13), and θ_(i16) have a second measurement, e.g., of about 110°; internal angles θ_(i2), θ_(i3), θ_(i10), and θ_(i11) have a third measurement, e.g., of about 145°; and internal angles θ_(i6), θ_(i7), θ_(i14), and θ_(i15) have a fourth measurement, e.g., of about 125°. Additionally, the external angles are not all same. In particular, as shown in FIG. 4A, external angles each of the external angles θ_(e1), θ_(e4), θ_(e5), and θ_(e8) have a first measurement, for example, of about 70°, while external angles θ_(e2), θ_(e3), θ_(e6), and θ_(e7) have a second measurement, for example, of about 110°. As also shown, the sides of the strengthening member 400 have differing lengths. In addition, the strengthening member 400 of the exemplary embodiment shown in FIGS. 4A-4B includes recessed areas 414, 415, 416 and 417 spaced around the perimeter of the strengthening member and extending along the length of the strengthening member 400, each recessed area 414-417 extending from first end 418 to second end 420 of strengthening member 400. As noted above, the embodiment of FIGS. 4A-4B is exemplary, and therefore all of the contemplated embodiments with variations to the lengths of the sides, thicknesses of the sides, the angles of the internal and external corner angles, and the aspect ratio of the of the twenty-four-cornered cross sections, with sixteen internal angles and eight external angles, of the strengthening members in accordance with the present teachings are not shown in the figures.

Top and perspective views of an alternative exemplary embodiment of a strengthening member 500 having the twenty-four-cornered cross section, with sixteen internal angles and eight external angles, are illustrated in FIGS. 5A-5B, respectively. In the exemplary embodiment of FIGS. 5A-5B, each of eight of the internal angles are about 90°, each of the other eight internal angles are about 135°, and each external angle is about 90°. As illustrated in FIG. 5A, the lengths of side walls 502B, 502D, 502H, 502J, 502N, 502P, 502T and 502V are greater in comparison to the lengths of side walls 502A, 502C, 502E-G, 5021, 502K-M, 5020, 502Q-S, 502U, 502W and 502X. This difference in the lengths of the sides provides recessed areas 514, 515, 516 and 517, each of which extends along the length of the strengthening member 500 from first end 518 to second end 520 of the strengthening member. These recessed areas 514-517 each have a depth δ₅₁₄-δ₅₁₇, which is increased (and may be considered relatively deep) in comparison to the recessed areas shown in the strengthening members illustrated in FIGS. 2A-4B. This type of parameter tuning, i.e., changing the lengths of the sides to increase the depth of the recess areas 514-517, can further improve the fit of the strengthening member 500 with other vehicle components. In particular, the combination of the increased depth of the recessed area and the increased length of the opposite walls (sides) of the recessed area work together to reduce the total volume of the strengthening member, thereby increasing the space around the exterior of the strengthening member in which other vehicle components may be permanently, temporarily or periodically fitted, located, or otherwise disposed. Such vehicle components may include, for example, brake line(s), pipe(s), electric wire(s), cable(s) and seatbelt(s). The side walls defining the recessed area can function as a shelter to protect the other vehicle components from being damaged during vehicle impact events.

Top and perspective views of an alternative exemplary embodiment of a strengthening member 600 having the twenty-four-cornered cross section, with sixteen internal angles and eight external angles, are illustrated in FIGS. 6A-6B, respectively. Similar to the strengthening member 300, strengthening member 600 tapers along its longitudinal axis 612 from a first end 618 of the strengthening member to a second end 620 of the strengthening member 600. The thickness of each sidewall 602A-602X is also substantially the same to each other side wall 602A-602X and throughout the longitudinal length of each side wall 602A-602X. However, as shown in FIGS. 6A-6B, strengthening member 600 differs from strengthening members 200 and 300 in that the length of each side of each side wall 602A-602X is not all the same. For example, as shown in FIG. 6A, the cross-sectional lengths of a first group of side walls 602A, 602E, 602G, 602K, 602M, 602Q, 602S and 602W are all substantially the same; the cross-sectional lengths of a second group of side walls 602B, 602D, 602H, 602J, 602N, 602P, 602T and 602V are all substantially the same; the cross-sectional lengths of a third group of side walls 602C, 6021, 602O, and 602U are all substantially the same; and the cross-sectional lengths of a fourth group of side walls 602F, 602L, 602R, and 602X are all substantially the same. However, as shown in FIG. 6A, for example, the cross-sectional length of each side wall in the aforementioned first group of side walls is different than the cross-sectional length of each side wall in the aforementioned second, third, and fourth groups of side walls; the cross-sectional length of each side wall in the aforementioned second group of side walls is different than the cross-sectional length of each side wall in the aforementioned third and fourth groups of side walls; and the cross-sectional length of each side wall in the aforementioned third group of side walls is different than the cross-sectional length of each side wall in the aforementioned fourth group of side walls.

The strengthening member 600 includes sixteen internal angles θ_(i1)-θ_(i16) and eight external angles θ_(e1)-θ_(e8). As shown in FIGS. 6A-6B, each of the internal angles θ_(i1)-θ_(i16) and each of the eight external θ_(e1)-θ_(e8) is an obtuse angle. In exemplary embodiment of FIGS. 6A-6B, for example, each of the internal angles θ_(i1), θ_(i4), θ_(i5), θ_(i8), θ_(i9), θ_(i12), θ_(i13), and θ_(i16) is about 117°; each of the internal angles θ_(i2), θ_(i3), θ_(i6), θ_(i7), θ_(i10), θ_(i11), θ_(i14), and θ_(i15) is about 135°; and each of the external angles θ_(e1)-θ_(e8) is about 135°. In addition, and in contrast to the strengthening member 500 shown in FIGS. 5A-5B, the lengths of side walls 602A, 602E, 602G, 602K, 602M, 602Q, 602S and 602W are shorter in comparison to the lengths of side walls 602C, 602I, 602O, and 602U. This difference in the lengths of the sides provides recessed areas 614-617, each of which extends along the length of the strengthening member 600 from first end 618 to second end 620 of the strengthening member 600. These recessed areas 614-617 have a depth δ₆₁₄-δ₆₁₇, respectively, which is decreased in comparison to the recessed areas shown in the strengthening members illustrated in FIGS. 5A-5B. However, the decreased depth of the recessed areas 614-617 may be compensated for by varying the internal and external angles of the strengthening member cross section. For example, as shown in FIGS. 6A-6B, increasing each of the internal angles θ_(i1), θ_(i4), θ_(i5), θ_(i8), θ_(i9), θ_(i12), θ_(i13), and θ_(i16) and/or the external angles θ_(e1)-θ_(e8) to larger than 90 degrees results in a recessed area 614 in which all walls of the recessed portion form an isosceles trapezoid shape (as opposed to the rectangular shaped recesses shown in the embodiments of FIGS. 2A-5B). This configuration may also provide a more stable crush due to obtuse nature of each of the internal angles and external angles θ_(e1)-θ_(e8).

Top and perspective views of an alternative exemplary embodiment of a strengthening member 700 having the twenty-four-cornered cross section, with sixteen internal angles and eight external angles, are illustrated in FIGS. 7A-7B, respectively. Strengthening member 700 has twenty-four corners 704A-P and 706A-H, and twenty-four side walls 702A-702X. Sixteen of the corners are internal angle corners 704A-704P and eight of the corners are external angle corners 706A-706H. Strengthening member 700 also has a first transverse axis 708, a second transverse axis 710, and a longitudinal axis 712. Although shown with its longitudinal axis 712 positioned substantially vertically, when strengthening member 700 (as well as all of the other various embodiments in accordance with the present teachings) is installed within a vehicle, the longitudinal axis 712 of the strengthening member may be oriented substantially horizontally. In this position, first transverse axis 708 may be oriented substantially horizontally and second transverse axis 710 may be oriented substantially vertically, as shown in FIG. 7A. When installed in such a position, the shape of strengthening member 700 facilitates reducing or preventing moisture collecting or pooling along portions of the walls of the strengthening member. For example, certain conventional strengthening members whose walls form adjacent external angles of 90 degrees or form rectangular, square, or U-shaped recesses or depressions may collect moisture or permit moisture to pool in the recesses, increasing the possibility of weakening of the strengthening member via rusting, stripping, cracking, etc. (i.e., any form of oxidation or other chemical or physical distortion which the material of manufacture of the strengthening member may be more susceptible to due to the presence of moisture).

In contrast, a strengthening member 700 does not include a recessed portion in which liquids or moisture remain for a long period of time. In particular, each of the internal angles θ_(i1)-θ_(i16) and external θ_(e1)-θ_(e8) have been selected such the walls of the strengthening member are angled relative to one another to promote shedding of any moisture or fluid that falls within any recessed portion of the strengthening member. For example, as shown in FIGS. 7A and 7B, strengthening member 700 includes a first recessed portion 714 defined by side walls 702B, 702C, and 702D. Internal angles θ_(i3), θ_(i4), θ_(i5), and θ_(i6), and external angles θ_(e1) and θ_(e2) are obtuse. As a result, side walls 702A-702E are sloped/angled side wall in such a manner that fluid impinging or collecting on side walls 702A-702E will run off and toward an end of side wall 702A due in part or in whole to gravitational forces. Similarly, for example, as shown in FIGS. 7A and 7B, strengthening member 700 includes second recessed portion 715 defined by side walls 702H, 702I, and 702J. Internal angles θ_(i7), θ_(i8), θ_(i9), and θ_(i10), and external angles θ_(e3)and θ_(e4) are obtuse. As a result, side walls 702G-702K are sloped/angled side wall in such a manner that fluid impinging or collecting on side walls 702G-702K will run off and toward an end of side wall 702K due in part or in whole to gravitational forces. Also included are a third recessed portion 716 defined by side walls 702N, 702O, and 702P; and a fourth recessed portion 717 between side walls 702T, 702U, and 702V.

Recessed portions 714-717 are relatively shallow. Recessed areas having reduced depths, such as those of strengthening member 700, can be advantageous other when vehicle components, such as electric cables/wires, fuel lines/pipes, brake lines/wires, and seatbelts, need to be run through or installed inside the internal space of a strengthening member.

Top and perspective views of an alternative exemplary embodiment of a strengthening member 800 having the twenty-four-cornered cross section, with sixteen internal angles and eight external angles, are illustrated in FIGS. 8A-8B, respectively. Similar to strengthening member 700, each of the internal angles θ_(i1)-θ_(i16) and each of the external angles θ_(e1)-θ_(e8) of strengthening member 800 are obtuse. The lengths of the sidewalls have been selected such that recessed areas 814-817 have a depth δ₈₁₄-δ₈₁₇, respectively, which is increased in comparison to the recessed areas shown in the strengthening members illustrated in FIGS. 7A-7B. Thus, strengthening member 800 provides an exemplary embodiment of a strengthening member in accordance with the present invention that can promote moisture shedding and also provide more space around the exterior of the strengthening member in which other vehicle components may be permanently, temporarily or periodically fitted, located, or otherwise disposed.

More generally, the various exemplary embodiments of the present teachings contemplate, for example, strengthening members with corners having different bend radii, with non-uniform cross sections, having non-symmetrical shapes, with sides having variable thicknesses, and/or having variable tapered sides. Various additional exemplary embodiments contemplate strengthening members that are bent and/or curved. Moreover, to further adjust a member's folding pattern and/or peak load capacity, various additional exemplary embodiments also contemplate strengthening members having trigger holes, flanges, and/or convolutions as would be understood by those of ordinary skill in the art. Combinations of one or more of the above described variations are also contemplated.

As discussed and embodied herein, the lengths S₁-S₂₄ and thicknesses T₁-T₂₄ of the sides of the strengthening member are tunable parameters of the strengthening member. The lengths S₁-S₂₄ and thicknesses T₁-T₂₄ of the sides may be tuned to provide desired characteristics in the strengthening member. For example, in the embodiment of FIGS. 3A-3B, these parameters are tuned to provide a strengthening member 300 with side walls and corners that are tapered along the longitudinal length of the strengthening member 300.

As discussed and embodied herein, the aspect ratio of a cross section of the strengthening member is a tunable parameter in accordance with the present teachings. The aspect ratio of a cross section of a strengthening member may be tuned to provide desired characteristics in the strengthening member. For example, in the embodiment of FIGS. 4A-4B, these parameters are tuned to provide a strengthening member 400 having two cross-sectional dimensions along perpendicularly oriented transverse axes that are substantially different in length the longitudinal length of the strengthening member 400.

As discussed and embodied herein, the lengths of the sides S₁-S₁₆ of the cross section is a tunable parameter in accordance with the present teachings. The lengths of the sides S₁-S₁₆ of a strengthening member may be tuned to provide desired characteristics in the strengthening member. For example, in the embodiment of FIGS. 5A-5B this parameter is tuned to provide a strengthening member 500 with recess areas 514-517 having particular depths δ₅₁₄-δ₅₁₇ that extend along the longitudinal length of the strengthening member 500.

As discussed and embodied herein, the sixteen internal angles θ_(i1)-θ_(i16) and eight external angles θ_(e1)-θ_(e8) are tunable parameters of the strengthening member. The internal angles θ_(i1)-θ_(i16) and external angles θ_(e1)-θ_(e8) may be tuned to provide desired characteristics in the strengthening member. For example, in the embodiment of FIGS. 6A-6B, these parameters are tuned to provide a strengthening member 600 with trapezoidal recessed areas 614-617 having a particular depths δ₆₁₄-δ₆₁₇ that extend along the longitudinal length of the strengthening member 600. Additionally, internal angles θ_(i1)-θ_(i16) and external angles θ_(e1)-θ_(e8) may be tuned to promote moisture shedding, as demonstrated in the embodiments of FIGS. 7A-7B and 8A-8B.

As discussed and embodied herein, multiple tunable parameters—including but not limited to the lengths S₁-S₂₄ and thicknesses T₁-T₂₄ of the sides of the strengthening member, the aspect ratio of a cross section of the strengthening member, the internal angles θ_(i1)-θ_(i16) and external angles θ_(e1)-θ_(e8) of the corners, and the depths δ₁₋δ₄ of the recess areas—may all be tuned within the same strengthening member. These parameters all may be tuned within the same strengthening member to provide desired characteristics in the strengthening member.

In the illustrated embodiments of FIGS. 2A-8B, the strengthening members may have a one-piece construction. As stated above, the one-piece constructions shown in FIGS. 2A through 8B are exemplary only and the present teachings contemplate strengthening members of other constructions such as two-piece construction or having three or more pieces.

To demonstrate the improved strength and performance features of a twenty-four-cornered cross section having sixteen internal angles and eight external angles in accordance with the present teachings, the inventors compared various existing and conventional strengthening member cross section designs to cross sections based on the designs disclosed herein. Exemplary strengthening members were modeled and crash simulation runs were conducted, as shown and described below with reference to FIGS. 9-13.

Strengthening members of varying shapes (i.e., cross sections) having the same mass, thickness, longitudinal length and the same cross-sectional lengths along perpendicular transverse axes were modeled as illustrated in FIG. 9. Crash simulations were then run for each member to simulate an impact with the same rigid mass (e.g., an impactor), impact speed, and initial kinetic energy.

FIG. 10 shows cross members which have undergone a simulated quasi-static crush. During each quasi-static crush the impact speed is slow (e.g., 1 in/min). An impactor compresses the members with a controlled displacement. Therefore, all members reach the same crush distance with the same crush time. Thus, subjecting multiple strengthening members to a quasi-static crush provides a comparison of the folding length and the crush stability of the strengthening members. As shown in FIG. 10, the twenty-four-cornered cross section in accordance with the present teachings demonstrated the most stable axial collapse and the smallest folding length.

FIG. 11 shows cross members which have undergone a simulated dynamic crush. During each dynamic crush, the impactor is propelled by a gas gun with a designated mass and initial impact velocity which creates a designated initial kinetic energy. The initial kinetic energy crushes the members. Performance of each strengthening member can be compared by measuring the crush distance and specific energy absorption of each strengthening member. As shown in FIG. 11, the twenty-four-cornered cross section in accordance with the present teachings also demonstrated the shortest crush distance.

FIG. 12 illustrates the dynamic crush force (in kN) and associated axial crush distance (in mm) for the simulated dynamic crush, exerted axially on the exemplary strengthening members having the cross sections shown in FIG. 9. As shown in FIG. 12, the strengthening member having a twenty-four-cornered cross section could sustain a much higher crushing force for a given resulting crushing distance as compared with the square, hexagonal, circular, octagonal, and twelve-cornered cross sections. Specifically, the twenty-four-cornered cross section in accordance with the present teachings achieved about a 104.2% increase in averaged crush force and/or crash energy absorption as compared with the octagon.

FIG. 13 illustrates the dynamic axial crush energy (in kN-mm) and associated axial crush distance (in mm) for a simulated dynamic crush exerted on the exemplary strengthening members having the cross sections shown in FIG. 9. As shown in FIG. 13, the strengthening member having a twenty-four-cornered cross section could absorb the same total kinetic energy of the impact over a much shorter distance as compared with the square, hexagonal, circular and octagonal cross sections. In particular, a twenty-four-cornered cross section in accordance with the present teachings absorbed the full axial crush energy in about 46.9% of the axial crush distance as the basic octagonal cross section.

Twenty-four-cornered cross sections in accordance with the present teachings may, therefore, allow improved impact energy management over, for example, basic polygonal strengthening member cross sections, including basic twenty-four-sided polygonal cross sections, while minimizing mass per unit length, provides mass saving solutions that reduce vehicle weight and meet new CAFE and emission standards.

Beyond the increased load carrying and energy absorption capabilities, strengthening members in accordance with the present teachings may provide additional advantages or benefits such as improved moisture shedding abilities (as noted above), increased bending energy absorption capacity, improved manufacturing feasibility, and better fitting of the shape amongst the other components of the complete device (e.g., vehicle, as noted above).

In addition, a twenty-four-cornered strengthening member in accordance with the present teachings also may be tuned to accommodate unique packaging requirements for use in various vehicles. By virtue of the particular shape of the cross section of at least some of the twenty-four-cornered cross members, it may be easier to couple, bond, attach, or otherwise affix other device components to the strengthening member. Other device components can include, but are not limited to, engine mounts or transmission mounts.

Twenty-four-cornered strengthening members in accordance with the present teachings are contemplated for use as structural members in a number of environments. For example, in a motor vehicle, a strengthening member as disclosed herein may be used, for example, as one or more of crush cans, front rails, mid-rails, rear rails, side rails, shotguns, cross members, roof structures, beltline tubes, door beams, pillars, internal reinforcements, and other components that can benefit from increased crash energy absorption or the other advantages described herein. In addition, the present teachings can be applied to both body-on-frame and unitized vehicles, or other types of structures.

For example, as shown in FIGS. 14 and 15, twenty-four-cornered strengthening members with sixteen internal angles and eight external angles in accordance with the present disclosure can be used to form part of or within a vehicle frame and/or a vehicle upper body. FIG. 14 illustrates an exemplary embodiment of a vehicle frame 1400 with several components for which the strengthening can be used. For example, the strengthening members in accordance with the present disclosure may form or be used as a part of a front horn 1402, a front rail 1404, a front side rail 1406, a rear side rail 1408, a rear rail 1410, and/or as one or more cross members 1412. Likewise, FIG. 15 illustrates an exemplary embodiment of a vehicle upper body 1500 with several components for which the strengthening can be used. For example, the strengthening members in accordance with the present disclosure may be formed or be used as a part of a shotgun 1502, a hinge-pillar 1504, an A-pillar 1506, a B-pillar 1508, a C-pillar 1510, one or more door beams 1512, a cross car beam 1514, a front header 1516, a rear header 1518, a cow top 1520, a roof rail 1522, a lateral roof bow 1524, longitudinal roof bow 1526, one or more body cross members 1528, and/or a body cross member 1530.

Moreover, the strengthening members in accordance with the present disclosure may be used as or form a part of vehicle underbody components, for example, as a rocker and/or one or more underbody cross members. Also, the strengthening members in accordance with the present disclosure may be used as or form a part of vehicle engine compartment components, for example, as one or more engine compartment cross members.

Depending on the application, embodiments of the present teachings will have varied shapes (i.e. various cross sections) to accommodate specific member space constraints. When used as a vehicle front rail, for example, to achieve optimized axial crush performance, the lengths and thicknesses of the sides and/or angles of the corners can all be adjusted (tuned) to provide optimal strength, size and shape to meet engine compartment constraints.

Although various exemplary embodiments described herein have been described as configured to be used with automotive vehicles, it is envisioned that the various strengthening members in accordance with the present teachings may be configured for use with other types of vehicles (e.g. aircrafts, spacecrafts and watercrafts) and/or structures, for which it may be desirable to provide increased crash energy absorption. Thus, it will be appreciated by those of ordinary skill in the art having the benefit of this disclosure that the present teachings provide strengthening members for various applications. Further modifications and alternative embodiments of various aspects of the present teachings will be apparent to those skilled in the art in view of this description.

It is to be understood that the particular examples and embodiments set forth herein are non-limiting, and modifications to structure, dimensions, materials, and methodologies may be made without departing from the scope of the present teachings.

In particular, those skilled in the art will appreciate that a strengthening member may include more than one longitudinal section or portion, with each section or portion having one or more of the variations taught in accordance with the present disclosure. Said variation(s) can be made continuously or intermittently along the length of each longitudinal section. In other words, strengthening members that embody combinations of one or more of the above variations to the disclosed tunable parameters, which have not been illustrated or explicitly described, are also contemplated.

For the purposes of this specification and appended claims, unless otherwise indicated, all numbers expressing quantities, percentages or proportions, and other numerical values used in the specification and claims, are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the written description and claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the present teachings are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all sub-ranges subsumed therein.

It is noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the,” include plural referents unless expressly and unequivocally limited to one referent. As used herein, the term “include” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items.

It will be apparent to those skilled in the art that various modifications and variations can be made to the devices and methods of the present disclosure without departing from the scope of its teachings. Other embodiments of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the teachings disclosed herein. It is intended that the specification and embodiment described herein be considered as exemplary only. 

What is claimed is:
 1. A strengthening member for a motor vehicle, the strengthening member comprising a cross-section including twenty-four corners and including sides and corners creating sixteen internal angles and eight external angles.
 2. The strengthening member of claim 1, wherein each internal angle ranges between about 30 degrees and about 175 degrees.
 3. The strengthening member of claim 1, wherein each external angle ranges between about 45 degrees and about 175 degrees.
 4. The strengthening member of claim 1, wherein eight of the sixteen internal angles are substantially equal to one another and wherein the other eight of the sixteen internal angles are substantially equal to one another.
 5. The strengthening member of claim 1, wherein each of the eight external angles is substantially the same.
 6. The strengthening member of claim 1, wherein at least one internal angle is a right angle.
 7. The strengthening member of claim 4, wherein eight of the internal angles are right angles.
 8. The strengthening member of claim 4, wherein each of the external angles is a right angle.
 9. The strengthening member of claim 1, wherein the strengthening member further comprises at least one recessed portion extending along a length of the strengthening member.
 10. The strengthening member of claim 7, wherein the at least one recessed portion is defined by two internal angles and two external angles of the strengthening member.
 11. The strengthening member of claim 8, wherein the two external angles defining the recessed portion are adjacent to one another.
 12. The strengthening member of claim 9, wherein the two external angles defining the recessed portion are equal to one another.
 13. The strengthening member of claim 9, wherein each of the two internal angles is obtuse.
 14. The strengthening member of claim 7, wherein the at least one recessed portion is defined by three sides of the strengthening member.
 15. The strengthening member of claim 12, wherein the three sides of the strengthening member defining the at least one recessed portion have the same length.
 16. The strengthening member of claim 12, wherein two of the three sides of the strengthening member defining the at least one recessed portion have the same length and the other of the three sides has a different length.
 17. The strengthening member of claim 1, wherein the corners of the cross section have substantially the same thickness as the sides of the cross section.
 18. The strengthening member of claim 7, further comprising four recessed areas, wherein each recessed area extends along a length of the strengthening member from a first end of the strengthening member to a second end of the strengthening member.
 19. A strengthening member for a motor vehicle, the strengthening member comprising a cross-section including twenty-four corners and including sides and corners creating internal angles and external angles that alternate between four consecutive internal angles and two consecutive external angles.
 20. The strengthening member of claim 17 further comprising a longitudinal axis, wherein the strengthening member tapers along the longitudinal axis.
 21. The strengthening member of claim 17, wherein the cross section has more than two bisecting planes of symmetry.
 22. The strengthening member of claim 19, wherein the cross section has four bisecting planes of symmetry.
 23. The strengthening member of claim 17, wherein at least one internal angle of the cross section varies along at least a portion of a length of the strengthening member.
 24. The strengthening member of claim 17, wherein a thickness of at least one side of the strengthening member varies along at least a portion of a length of the strengthening member.
 25. A vehicle comprising: a strengthening member comprising a cross section including twenty-four corners and including sides and corners creating sixteen internal angle corners and eight external angle corners.
 26. The vehicle of claim 23, wherein the strengthening member is, or is within, at least one vehicle structural member selected from the group consisting of: a crush can, a front horn, a front rail, a front side rail, a rear side rail, a rear rail, a frame cross member, a shotgun, a hinge-pillar, an A-pillar, a B-pillar, a C-pillar, a door beam, a cross car beam, a front header, a rear header, a cow top, a roof rail, a lateral roof bow, longitudinal roof bow, a body cross member, a back panel cross member, a rocker, an underbody cross member, and an engine compartment cross member. 